2003-2007 Ford Powerstroke EGR System – Where it is, Why it is a Problem, and What to Do About It

In 2003 Ford introduced the 6.0 Powerstroke to the globe. This is the same engine that International calls the VT365. This engine has actually received a truly negative credibility in the diesel globe as a result of integrity concerns. We will tackle one of the problem locations below today, the EGR system.

Prior to I go any kind of further, please comprehend that the EGR system is an exhausts tool. It protests Federal regulation to tamper, remove, or render a discharges system inoperable. Please comprehend that all the information in this short article was accumulated from off-road just trucks and I do not supported the elimination or damaging of any emissions system of a vehicle that is utilized on public roads. All the information obtained for this post is from testing lorries on our Superflow chassis dyno in the shop. It depends on you and also your mechanic to decide what steps you intend to take in customizing your truck. Use this details at your personal risk.;-RRB-.

What is the EGR system and why do I require it?

Among one of the most faqd we obtain is just what is the EGR system and why do I need it? We don’t have to go right into lengthy technical summaries here. EGR means Exhaust Gas Recirculation. To satisfy certain discharges criteria, it is necessary to reestablish exhaust gases right into the intake air in order to bring particular components in the exhaust within degrees established for that year of vehicle. Certainly you would not wish to dispose warm exhaust gas directly into the consumption manifold, to ensure that is why there is an EGR colder. The colder has engine coolant going through it and looks significantly like a normal radiator or heating unit core. The exhaust gas passes through this small radiator and lowers the exhaust gas to a temperature level that it has the ability to be introduced into the intake system at. On the 6.0 Powerstroke engine, it is a very simple system consisting just of a cooler and a shutoff. When the engine’s computer decides the EGR valve need to open up under particular conditions, the exhaust gas is discharge of the cooler as well as right into the consumption manifold. And also right here we have the very first hint of an issue; the exhaust gas is constantly in the EGR cooler.

What fails with the EGR system as well as how can it injure my engine?

The huge trouble right here is warmth. It is possible for an entirely supply engine to generate exhaust gas temperatures well over of 1000 degrees. So imagine taking 1000-1500 level air and also continuously running it through your heating system core day in day out. How much time do you believe it would certainly last? Next, placed that heating system core in a confined box that needs to endure not only the high temperatures, however also 10-50 psi of exhaust backpressure that is constructed before the turbo it as well as the exhaust manifold. Although the cooler is constructed out of materials that are meant for greater temperatures, it is not a matter of if, yet when your cooler will fail. Best situation scenario is that the cooler just leaks a little coolant right into the exhaust system as well as it loses consciousness the exhaust as well as you just discover some coolant loss. Worst situation circumstance, exhaust stress is able to enter a break in the colder and go into the coolant system which only goes for 12 approximately psi max. The high stress will destroy head gaskets as well as oil colders. They just weren’t created to hold up against that much stress in the coolant system. Also, the coolant system can not maintain the vehicle cool with that said much stress in the system. This is why you will find out about or may have experienced coolant throwing up from the filler cap on the degas container after pulling a load up a long hill. The cap is made to bleed off stress over 12-14 psi. The increased coolant temperature as well as extra stress being pushed in from the exhaust will certainly push coolant right out the cap. We have a vehicle in the store today with a blown EGR colder and also head gasket. The pressure in the coolant system had gotten so high that it blew one of the tubes right off the coolant container. This vehicle was a bone stock work vehicle. This blown cooler issue just becomes worse when you placed a programmer on the truck that increases exhaust gas temperatures numerous hundred levels. If you place your designer on the highest possible setup, hook to a heavy trailer, then go tugging up a lengthy grade, I recommend you place your auto mechanic on speed dial. You will require his services quickly.

The other issue with the system is that the EGR valve constantly obtains colad up with exhaust residue. The filthy exhaust gas passing by it deposits residue on the valve surface areas. One way or another the valve will certainly obtain sufficient residue on it that it cannot shut as well as run typically. Exhaust gas is continuously pouring into the intake manifold currently. This problem causes serious drivability problems, bad gas economic climate, and low power. If you have owned a 6.0 Powerstroke for very long, you believe changed, cleaned up, or had to 6.0 egr delete because of this issue.

What can we do to fix this trouble?

There are a couple of solutions to this problem. The initial and most evident is to simply get rid of the cooler. Unfortunately, that would certainly be against the legislation. We do sell an EGR remove kit to do simply that if you are going to use your vehicle for off road just. This package completely removes the cooler from the vehicle. There is a line that bypasses the coolant from where it comes out of the oil cooler straight to where it once appeared of the EGR cooler into the consumption manifold. There is also a pipeline that replaces the manufacturing facility up-pipe in between the exhaust manifold and the turbo. Some years have an inside story in the factory pipeline in order to help direct exhaust gas right into the colder. Since the cooler isn’t mosting likely to exist any longer, we should change that pipe with one that does not have the flange for the colder nor the inside story. There is some discussion on just how much distinction in performance changing the up-pipe in fact makes, but I directly would similar to the foolish dig of there if it was my truck. Also, we are getting rid of one more place to have an exhaust leak by not leaving the factory cooler flange with some kind of enclose in it.

The other fix is to replace the cooler with a “efficiency” one that is not suppose to fracture. I have never personally installed among these myself. I actually do not believe in them. Even if the cooler will never ever stand out with a better device in there, you would still be obtaining exhaust gas right into the consumption system. If you have ever before torn down a 6.0 Powerstroke, you would certainly be amazed at the amount of soot that gathers on the intake passages and consumption valves. Letting filthy exhaust gas into the intake manifold is just a poor concept the whole method around. If you are on a tight spending plan, still under guarantee, or fretted about not having the cooler in there for emissions, you might simply block the stock cooler off. The quickest and best reduced budget plan repair is to put a freeze plug in either end of the colder as well as weld it strong. This way no exhaust gas could enter the colder neither can any kind of coolant exit if the cooler ever before ruptured. You still have the issue of the scoop in the exhaust pipe, however this reduced buck repair will certainly function OKAY if you can not manage the erase package to do it right. With this being said, I would certainly still mount the bypass kit on my very own personal truck simply to be eliminate the whole mess for good.

Will erasing the cooler influence the means my vehicle runs? Will I obtain a check engine light?

The response to the very first inquiry is indeed. You should see a boost in fuel gas mileage, a little quicker spool up of the turbo, and generally a little reduced EGT’s. There are no negative performance results from removing the cooler regardless of what your pleasant Ford specialist informs you. It feels like a waste of your cash to set up a high circulation air filter or cool air consumption system if you have hot, filthy exhaust gas putting into the system simply past it. When it comes to the check engine light, you should not obtain one at all as lengthy as you leave the EGR valve in the manifold as well as plugged in. There is absolutely no need to remove it from the system once you have actually gotten rid of the colder. The computer can open up as well as close it as often times as it desires. There is no responses loop that lets the computer system understand whether the exhaust gas made it into the consumption manifold when the shutoff is open. The computer will certainly stay happy just opening up as well as shutting the shutoff at will and no check engine light will certainly be lit. There are some remove kits out there that have an enclose plate for the port where the EGR shutoff goes. I don’t recommend installing them. For beginners, there is no need to block it off if you have actually the cooler removed considering that no exhaust can get through the valve. Second, you will need to leave the valve plugged in as well as laying on the engine to fend off check engine lights which is type of inexperienced at best.

Is there anything I can do to lengthen my EGR cooler life if I intend to leave it in?

If you don’t intend to eliminate your cooler for worry of black helicopters and jail time for tampering with Federal discharges gadgets, there are a number of things you can do. First of all, the reduced you could keep your exhaust gas temperature levels the far better. Mounting a high flow exhaust will certainly aid decrease your EGTS considerably. A larger more efficient intercooler like the Financial institutions Technicooler or the Spearco upgrade will additionally assist. Mounting a turbo that relocates much more air like the Garrett Stage 1 will certainly additionally assist lower EGTS. And lastly, setting up a pyrometer to keep on eye on exhaust gas temperatures will allow you to back out of the throttle when they get expensive. Also ensuring you run oil that has the ideal qualification for your engine will aid maintain soot down a little.

In conclusion, I firmly think all the horror tales of several blown head gaskets could be blamed on 2 points: First is exceptionally high timing in several of the first performance programmers that were introduced. They merely didn’t know right away that the 6.0 would vomit the gaskets if more than 12 levels of timing was utilized for the truly warm programs. The 7.3’s would withstand that much timing as well as even more no worry. Second of all, I believe blown EGR coolers added to then and also still are triggering blown head gaskets today. I understand the need for cleaner emissions, but at what cost?